Composite molding



W. H. KEMPTON. COMPOSITE MOLDING.

APPLICATION FILED JULY 25. l9l8.

PatentedSept. 27,1921.

INVENTOR Wife/ll h. limp/022 AJI'TORNEY WITNESSES:

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UNITED STATES PATENT-OFFI E.

WILLARD E. KEMPTON, OF WIIiKINSBURG, PENNSYLVANIA, ASSIGNOB. TO WESTING- HOUSE ELECTRIC & MANUFACTURING COMPANY, A. CORPORATION 01' PENNSYL- VANIA.

comrosrrn momma.

1 Application filed July 25, 1918. Serial No. 246,783.

To all. whom it may concern Be it known that I, WILLARD H. KEMP- won, a citizen of the United States, and a resident of Wilkinsburg in the county of Allegheny and State of lennsylvania, ave invented a new and useful Improvement in Composite Molding, of which the following is a specification.-

My inventionrelates to composite molding, and ithas for its primary object the moldin of composite articles by a method that wi l insure mechanical strength and the pro er disposition of the employed material mt e resulting article.

' Heretofore, to the best of my knowledge, in molding articles inwhich a lubricant, such as graphite is utilized, it has been customary to distribute the graphite throughout the entire structure 0 the article to be molded. On account of the low adhesive pro erties of the graphite, this distribution ten s to reduce the mechanical strength of the molded article. In view of this, one object of my invention is to mold composite articles, containing gra hite as a lubricant, so that the graphite s all be localized in that, portion of the molded article requiring the lubricant and to minimize, in this way, the weakening effect of the graphite. n It is desirable that some articles, such, for instance, as machine elements, have selflubricating qualities and, at the same time, be non-conductors o electricity. In such instances the use of graphite, in any considerable. quantity, as a lubricant is prohibited, if distributed throu bout the entire structure of the article, %or the reason that the graphite, being a good conductor, permits the passage of .current through the article. Because of this, vention is to construct a composite molded article comprising two or more molding compositions, one of which contains graphite as a lubricant and the other of which is no1i-conducting, the composition being so positioned, relative to each other,th'a,t the fdesired properties, both of insulation and lubrication are attained.

I cant needed to insure proper efliciency.

, further object of my invention is to construct a composite article, having the lubricant, employed in its composition, so localized as to reduce the amount of lubriviews of which correspon dicate like parts, and then particularly another object of my in- A still further object of my invention is to employ a method of molding composite "articles which may provide two .wOrking surfaces, one of which shall have a much hi her co-eflicient of friction than the other.

with these and other objects in view, my invention will be more fully described illustrated in the drawin ,in the severa ing numerals inpointed out in the ap ended claims.

In the drawings, igure 1 is avertical ,Patented Sept 2'7, 1921.

section of a mold embodying my invention and showing the. initial step in molding a compositearticle, such as a pulley or roller; Flg. 2 is a sectional view, similar to Fi n -1, in which the two materials employed in molding a. composite article are shown positioned'in the mold previousv to the application of pressure to complete the compacting of the materials; Fig. 3 is a sectional view, similar to Fig. 2, showing the ressure members in their final positions; ig. 4 is a sectional view, similar to Fig. 3, illustratmg a modification of my invention; Fig. 5

is a sectional view of a mold which may be employed in constructing articles having a different disposition of materials therein; Fig. 6 'is a sectional view, showing another shghtly modified mold by whichcams and articles of similar nature may be formed in accordance with my invention, and'Fig. 7 is a sectional view of a member employed in place of one of the members shown in 6, during one step of 'mymethod.

n practising my invention, I may employ a mold in which a molding material having great mechanical strength, as well as insulating properties, maybe positioned and shghtly compressed about a spacing memher which may be removedafter the materia'l about it has been slightly compressed. The subsequent removal of the spacing memhe!- provides an opening in which another material, having a lubricantuniformly distributed in it, may be placed, after which, pressure members, adapted to e go the two materials thus disposed in t e mold, may be placed thereon and pressure exerted to compact both the materials into a hard unitary article. Heat may be applied throughout th entire molding process or I after the materials have been compressed, as y seems most desirable. The positioning and treatment of the materials placed in the mold will be more fully described in the followingparagraphs.

In Fig. 1 is shown a mold body 1, having a chamber 2 opening through its ends and closed at-one end by a removable bottom 3 having an opening 4 in which one end of 'a centermg pin or rod 5 may be placed. If the composite article, to be molded in accordance with my invention, is in the nature of a pulley or roller requiring a cylindrical axial opening, the bottom 3 will be provided with a centralv opening 4 in which one end of the rod 5 may be placed, thus disposing the rod axially of the chamber 2. A spacing member or sleeve 6, having an opening 7 to receive the rod 5, may then be slipped over the rod 5, and molding material 8 may be placed around the spacing member 6 to rest on the bottom 3 and fill the space between the mold body 1 and sleeve 6 to the desired depth. A pressure ring 9 may then be placedbetween the spacing member 6 and the inner wall of the mold 1 and pressure may be applied to this ring to compress the material sufficiently to compact it, as shown in Fig. 1, so that, when the spacing member 6 is removed, the material will retain its position and form.

Another molding material 10, containing a lubricant such as graphite, may now be placed in the space provided by removing the spacing member 6 and a pressure me'm ber or ring 11 similar to the pressure member 9 may be placed about the rod 5 to en gage the material last added and, with the.

member 9 and rod 5, completely close the top of the chamber 2, whereby pressure may be applied to the entire surfaceof the material disposed in the mold. Pressure may then be applied uniformily to the pressure members 9 and 11, while the mold is heated, thus compressing the twomaterials in the mold to form a solid unitary body.

In molding articles of the above described character, the material 8, whichisfirst ositioned in the mold and subjected to slight compression may be a shredded material, a fabric, .a loose fibrous materiah such as cotton batting, or a granular or finely divided material, such as wood flour, the material,

whatever it may be, being impregnated with a suitable binder such, for example, as a phenolic condensation product. When loose material is employed, an initial pressure, transmitted by the pressure member 9, is essential to compact the material 8 so that it will retain its position and shape when the spacing member 6 is removed. The material 10, which is employed to partially fill the space provided by the removal of the spacing member 6, may be the same as the material 8, with a lubricant, such as graph ite, distributed through it.

The mold shown in Fig. 4 may be employed to construct an article composed of material of a difierent character than the material above mentioned. .The material 12 may be a fibrous sheet material such as paper, duck or muslin, impregnated with a binder containing a lubricant. The material 12 may be wound to form a tube of such proportions that, when placed in the mold 1, it will engage the wall of the mold and remain in spaced relation to the centering rod 5. On account of the ability of the material 12, which is first placed in the mold 1, to maintain its position and shape, the mold 1 differs from the molds shown in Figs. 1 to 3 inclusive in that no spacer member is needed and the pressure member 13 replaces both the pressure members 9 and 11. The material 8, which may be utilized to fill the space between the rod 5 and the material 12, may be a loose fibrous material or a sheet material, impregnated with a suitable binder, such as a phenolic condensation product. If the material 8 is a sheet material, it may be wound to form a tube of proper dimensions. The pressure member 13, having a central opening 7, may be slipped over the rod 5 to engage the materials disposed in the mold 1 and pressure applied thereto, while the mold is heated, to compact the materials into a hard and unitary body. a

The mold shown in Fig. 5 corresponds, in detail, to the'mold illustrated in Fig. 4, this view being employed in order to illustrate another disposition of materials in the mold. In this case, the material 12 may be wound about the centering rod 5 to a suitable thickness and placed in the mold so that a space is reserved between the material 12 and the wall of the mold 1 which may be filled by the material 8. The pressure member 13 may then be placed on the materials in the mold 1 and pressure and heat may be applied to com act the materials into a hard and unitary bod Fig. 6 illustrates one type of mold embodying my invention whlch may be employed in constructin cams and articles of a, similar nature. ig. 7 shows the spacing member 14 which replaces the spacing member 6, shown in Fig. 1, and has the opening 7 so formed as to be in alinement with the eccentrically located opening 4 in the bottom 12, corresponding to the bottom 3. The spacing member 14 may be slipped over 'the centering rod 5, and the material 10, which is the material containing the lubricant, may be placed in the mold l and subjected to slight compression transmitted 14 but is of less length, ma .be positioned about the centering rod 5 so t at, in conjunction with the the mold, heat being applied either during or after this compression. M

It is obvious that, althou h the molds described and illustrated in rawings are cylindrical, various shapes may beem loyed,

especially in the construction of sel -lubrieating gears or cams which must have 1rre ular surfaces.

lthough I have specifically1 described sevspirit of my invention and I desire, therefore, that no limitations shall be imposed except such as are indicated in the appende claims. w

I claim as my invention: 1. A composite molded article comprising a body portion composed of insulating material impregnated with a hardened binder and aninsert of similar material containing a lubricant.

2. A composite molded article comprising a body portion composed of insulating material impregnated with .a hardened binder ressure member 9, pressure may be applie to compact the materials in and an insert of similar materialcontaining graphite.

3. A composite molded article comprisin a body portion composed of a laminate material impregnated with a hardened binder and an insert of similar" material con: 4

taining a lubricant.

4. A composite molded article comprising a body portion composed'of a laminated material impregnated with a phenolic con densation product which has been hardened and an insert of material I containing graphite.

5. A composite molded article comprising a body portion composedof a materiaLhav:

ing relatively great mechanical and dielectrio strength and an insert of material containing a lubricant. -/-'T' 6. A com osite article comprising a'body portion .of brous material, a wearing ortion comprising a separate layer unite to said body portion, said wearing portion only containing a lubricant.

7. A com osite article comprising a body portion of brous material, a 'weari portion comprising a separate layer of, brous e0 material united to said body POItlOIlySEld wearing portion only-containing a lubricant and being held to said body portion by 'a hardened binder.

I In testimony whereof, I have hereunto 5 subscribed my name this 22nd day oi July I I WILLARD H. KEMPTQN. v 

